Yamaha XVS650 Page 75 Owner'S Manual Download

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PERIODIC MAINTENANCE AND MINOR REPAIR

6-23

EAU00711*

Adjusting the brake pedal
position and free play

EW000104

WARNING

It is advisable to have a Yamaha
dealer make these adjustments.

NOTE:

The brake pedal position should be ad-
justed before adjusting the brake pedal
free play.

Brake pedal position

The brake pedal should be positioned
approximately 82 mm (3.23 in) [XVS650]
or 108 mm (4.25 in) [XVS650A] above
the top of the footrest as shown. Periodi-
cally check the brake pedal position and,
if necessary, adjust it as follows.

1. Loosen the locknut at the brake

pedal.

2. To raise the brake pedal, turn the

adjusting bolt in direction

. To

lower the brake pedal, turn the ad-
justing bolt in direction

3. Tighten the locknut.

EWA00044

WARNING

After adjusting the brake pedal posi-
tion, the brake pedal free play must
be adjusted.

a. Distance between brake pedal and footrest
b. Brake pedal free play

XVS650

a. Distance between brake pedal and footrest
b. Brake pedal free play

XVS650A

1. Locknut
2. Brake pedal position adjusting bolt

Summary of Contents for XVS650

Page 1: ...LIT 11626 15 15 OWNER S MANUAL 5FB 28199 11 XVS650P C XVS650AP C ...

Page 2: ...EAU03438 ...

Page 3: ...basic maintenance of this motorcycle If you have any questions concerning the operation or maintenance of your motorcycle please consult a Yamaha dealer The design and manufacture of this Yamaha motorcycle fully comply with the emis sions standards for clean air applicable at the date of manufacture Yamaha has met these standards without reducing the performance or economy of operation of the moto...

Page 4: ...ial precautions that must be taken to avoid damage to the motorcycle NOTE A NOTE provides key information to make procedures easier or clearer NOTE This manual should be considered a permanent part of this motorcycle and should remain with it even if the motorcycle is subsequently sold Yamaha continually seeks advancements in product design and quality Therefore while this manual contains the most...

Page 5: ...MOTOR CYCLE DO NOT ATTEMPT TO OPERATE THIS MOTORCYCLE UNTIL YOU HAVE AT TAINED ADEQUATE KNOWLEDGE OF ITS CONTROLS AND OPERATING FEATURES AND UNTIL YOU HAVE BEEN TRAINED IN SAFE AND PROPER RIDING TECHNIQUES REGULAR INSPECTIONS AND CAREFUL MAINTENANCE ALONG WITH GOOD RIDING SKILLS WILL ENSURE THAT YOU SAFELY ENJOY THE CAPABILITIES AND THE RELI ABILITY OF THIS MOTORCYCLE ...

Page 6: ... C XVS650AP C OWNER S MANUAL 2001 by Yamaha Motor Corporation U S A 1st edition April 2001 All rights reserved Any reprinting or unauthorized use without the written permission of Yamaha Motor Corporation U S A is expressly prohibited Printed in Japan P N LIT 11626 15 15 ...

Page 7: ...CRIPTION 2 3 INSTRUMENT AND CONTROL FUNCTIONS 3 4 PRE OPERATION CHECKS 4 5 OPERATION AND IMPORTANT RIDING POINTS 5 6 PERIODIC MAINTENANCE AND MINOR REPAIR 6 7 MOTORCYCLE CARE AND STORAGE 7 8 SPECIFICATIONS 8 9 CONSUMER INFORMATION 9 INDEX EAU00009 ...

Page 8: ...SAFETY INFORMATION 1 Safe riding 1 1 Protective apparel 1 3 Modifications 1 3 Loading and accessories 1 3 Gasoline and exhaust gas 1 5 Location of important labels 1 7 ...

Page 9: ...OR WHEN MADE NECESSARY BY MECHANICAL CONDITIONS Safe riding 1 Always make pre operation checks Careful checks may help prevent an accident 2 This motorcycle is designed to carry the operator and a passenger 3 The failure of motorists to detect and recognize motorcycles in traffic is the predominating cause of automobile motorcycle accidents Many accidents have been caused by an automobile driver w...

Page 10: ...ue to EXCESSIVE SPEED or undercornering in sufficient lean angle for the speed a Always obey the speed limit and never travel faster than warranted by road and traffic conditions b Always signal before turning or changing lanes Make sure that other motorists can see you 6 The posture of the operator and passenger is important for proper control a The operator should keep both hands on the handleba...

Page 11: ...during or after operation They become very hot and can cause burns Always wear protective clothing that covers your legs ankles and feet 6 Passengers should also observe the precautions mentioned above Modifications Modifications made to this motorcycle not approved by Yamaha or the removal of original equipment may render the motorcycle unsafe for use and may cause severe personal injury Modifica...

Page 12: ...front fork or front fender These items in cluding such cargo as sleeping bags duffel bags or tents can create unstable handling or slow steering response Accessories Genuine Yamaha accessories have been specifically designed for use on this motorcycle Since Yamaha cannot test all other accessories that may be available you must personally be responsible for the proper selection installation and us...

Page 13: ... may limit control ability therefore such accessories are not recommended 2 Use caution when adding electrical accessories If electrical accessories exceed the capacity of the motorcycle s electrical system an electric failure could result which could cause a dangerous loss of lights or engine power Gasoline and exhaust gas 1 GASOLINE IS HIGHLY FLAMMABLE a Always turn the engine off when refueling...

Page 14: ...open flame otherwise it could catch fire 4 When transporting the motorcycle in another vehicle make sure that it is kept upright and that the fuel cock is turned to ON or RES for vacuum type OFF for manual type If it should lean over gasoline may leak out of the carburetor or fuel tank 5 If you should swallow any gasoline inhale a lot of gasoline vapor or allow gasoline to get into your eyes see y...

Page 15: ...SAFETY INFORMATION 1 1 7 EAU02977 Location of important labels Please read the following important labels carefully before operating this motorcycle ...

Page 16: ...SAFETY INFORMATION 1 1 8 1 2 3 XVS650 3 XVS650A 4 ...

Page 17: ...SAFETY INFORMATION 1 1 9 5 6 California only ...

Page 18: ...DESCRIPTION 2 Left view XVS650 2 1 Right view XVS650 2 2 Left view XVS650A 2 3 Right view XVS650A 2 4 Controls and instruments XVS650 XVS650A 2 5 ...

Page 19: ...iew XVS650 1 Shift pedal page 3 4 2 Fuel cock page 3 8 3 Starter choke knob page 3 9 4 Shock absorber assembly spring preload adjusting ring page 3 14 5 Helmet holder page 3 12 6 Storage compartment page 3 13 7 Owner s tool kit page 6 1 ...

Page 20: ...SCRIPTION 2 2 2 Right view XVS650 8 Engine oil filter element page 6 11 9 Battery page 6 31 10 Fuses page 6 33 11 Main switch steering lock page 3 1 12 Air filter element page 6 15 13 Brake pedal page 3 5 ...

Page 21: ...S650A 1 Shift pedal page 3 4 2 Fuel cock page 3 8 3 Starter choke knob page 3 9 4 Shock absorber assembly spring preload adjusting ring page 3 14 5 Helmet holder page 3 12 6 Storage compartment page 3 13 7 Owner s tool kit page 6 1 ...

Page 22: ...CRIPTION 2 4 2 Right view XVS650A 8 Engine oil filter element page 6 11 9 Battery page 6 31 10 Fuses page 6 33 11 Main switch steering lock page 3 1 12 Air filter element page 6 15 13 Brake pedal page 3 5 ...

Page 23: ... and instruments XVS650 XVS650A 1 Clutch lever page 3 4 2 Left handlebar switches page 3 3 3 Speedometer unit page 3 2 4 Fuel tank cap page 3 6 5 Right handlebar switches page 3 3 6 Throttle grip page 6 17 7 Brake lever page 3 5 ...

Page 24: ...ver 3 4 Shift pedal XVS650 3 4 Shift pedal XVS650A 3 4 Brake lever 3 5 Brake pedal 3 5 Fuel tank cap 3 6 Fuel 3 7 Fuel cock 3 8 Starter choke knob 3 9 Seats XVS650 3 9 Seats XVS650A 3 11 Helmet holder 3 12 Storage compartment 3 13 Adjusting the shock absorber assembly 3 14 Luggage strap holders 3 15 Sidestand 3 15 Ignition circuit cut off system 3 16 ...

Page 25: ...off The key can be removed EAU00040 LOCK The steering is locked and all electrical systems are off The key can be re moved To lock the steering 1 Turn the handlebars all the way to the left 2 Push the key in from the OFF po sition and then turn it to LOCK while still pushing it 3 Remove the key To unlock the steering Push the key in and then turn it to OFF while still pushing it EW000016 WARNING N...

Page 26: ...ave a Yamaha dealer check the self diagnosis system NOTE _ This warning light comes on for a few seconds when the key is turned to ON but this does not indicate a mal function _ EAU00095 Speedometer unit The speedometer unit is equipped with a speedometer an odometer and a tripmeter The speedometer shows riding speed The odometer shows the total distance traveled The tripmeter shows the distance t...

Page 27: ...d manually by pushing the switch in after it has re turned to the center position NOTE _ The self canceling system only oper ates when the motorcycle is moving so that the turn signal lights will not self cancel while you are stopped at an in tersection _ EAU00129 Horn switch Press this switch to sound the horn EAU03890 Engine stop switch Set this switch to before starting the engine Set this swit...

Page 28: ...ation of the ignition circuit cut off system EAU00157 Shift pedal XVS650 The shift pedal is located on the left side of the engine and is used in com bination with the clutch lever when shifting the gears of the 5 speed con stant mesh transmission equipped on this motorcycle EAU01215 Shift pedal XVS650A The shift pedal is located on the left side of the engine and is used in com bination with the ...

Page 29: ...ted at the right handlebar grip To apply the front brake pull the lever toward the handle bar grip EAU00162 Brake pedal The brake pedal is on the right side of the motorcycle To apply the rear brake press down on the brake pedal 1 Brake lever 1 Brake pedal XVS650 1 Brake pedal XVS650A ...

Page 30: ... Insert the fuel tank cap into the tank opening with the key inserted in the lock and with the marks on the cap and tank aligned 2 Turn the key counterclockwise to the original position remove it and then close the lock cover NOTE _ The fuel tank cap cannot be installed unless the key is in the lock In addition the key cannot be removed if the cap is not properly installed and locked _ EW000024 WA...

Page 31: ...exhaust sys tem _ Your Yamaha engine has been de signed to use regular unleaded gaso line with a pump octane number R M 2 of 86 or higher or a research octane number of 91 or higher If knocking or pinging occurs use a gasoline of a different brand or premi um unleaded fuel Use of unleaded fuel will extend spark plug life and reduce maintenance costs Gasohol There are two types of gasohol gaso hol ...

Page 32: ...ith the fuel cock lever in this position fuel flows to the carburetors Turn the fuel cock lever to this position when starting the engine and riding RES This indicates reserve With the fuel cock lever in this position the fuel re serve is made available Turn the fuel cock lever to this position if you run out of fuel while riding When this occurs refuel as soon as possible and be sure to turn the ...

Page 33: ... in direction b to turn off the starter choke ECA00038 CAUTION _ Do not use the starter choke for more than 3 minutes as the exhaust pipe may discolor from excessive heat In addition extended use of the starter choke will cause after burning If this occurs turn off the starter choke _ EAU01889 Seats XVS650 Passenger seat To remove the passenger seat Remove the nut and then pull the pas senger seat...

Page 34: ...ove the rider seat 1 Remove the passenger seat 2 Remove the bolts and then pull the seat up To install the rider seat 1 Insert the projection on the front of the rider seat into the seat holder as shown place the seat in the original position and then install the bolts 2 Install the passenger seat NOTE Make sure that the seats are properly secured before riding 1 Bolt 2 2 Seat holder 3 Projection ...

Page 35: ...To install the passenger seat Insert the projections on the front of the passenger seat into the holders as shown place the seat in the original position and then install the bolt Rider seat To remove the rider seat 1 Remove the passenger seat 2 Remove the bolt and then pull the rider seat up 1 Bolt XVS650A 1 Seat holder 2 2 Projection 2 XVS650A 1 Bolt XVS650A ...

Page 36: ... that the seats are properly secured before riding _ EAU00260 Helmet holder To open the helmet holder insert the key into the lock and then turn the key as shown To lock the helmet holder place it in the original position and then remove the key EW000030 WARNING Never ride with a helmet attached to the helmet holder since the helmet may hit objects causing loss of control and possibly an accident ...

Page 37: ...key into the lock and then turn it clockwise 2 Pull the storage compartment cov er out as shown To close the storage compartment 1 Place the storage compartment cover in its original position as shown 2 Turn the key counterclockwise re move it and then close the lock cover 1 Storage compartment cover 2 Storage compartment lock cover 3 Storage compartment lock 1 Storage compartment 2 Storage compar...

Page 38: ... procedures 2 To increase the spring preload and thereby harden the suspen sion turn the adjusting ring in di rection a To decrease the spring preload and thereby soften the suspension turn the adjusting ring in direction b NOTE Align the appropriate notch in the adjusting ring with the position in dicator on the shock absorber Use the special wrench and exten sion bar included in the owner s tool...

Page 39: ...erwise it may explode due to excessive gas pressure Do not deform or damage the gas cylinder in any way as this will result in poor damping per formance Always have a Yamaha dealer service the shock absorber EAU01172 Luggage strap holders There is a luggage strap holder on each passenger footrest EAU00330 Sidestand The sidestand is located on the left side of the frame Raise the sidestand or lower...

Page 40: ...epair it if it does not function properly EAU03720 Ignition circuit cut off system The ignition circuit cut off system com prising the sidestand switch clutch switch and neutral switch has the fol lowing functions It prevents starting when the trans mission is in gear and the side stand is up but the clutch lever is not pulled It prevents starting when the trans mission is in gear and the clutch l...

Page 41: ...the sidestand up 7 Keep the clutch lever pulled 8 Shift the transmission into gear 9 Move the sidestand down Does the engine stall After the engine has stalled 10 Move the sidestand up 11 Keep the clutch lever pulled 12 Push the start switch Does the engine start The sidestand switch may be defective The motorcycle should not be ridden until checked by a Yamaha dealer The clutch switch may be defe...

Page 42: ...PRE OPERATION CHECKS 4 Pre operation check list 4 1 ...

Page 43: ...e for leakage 3 7 Engine oil Check oil level in engine If necessary add recommended oil to specified level Check vehicle for oil leakage 6 11 Final gear oil Check vehicle for oil leakage 6 14 Front brake Check operation If soft or spongy have Yamaha dealer bleed hydraulic system Check lever free play Adjust if necessary Check fluid level in reservoir If necessary add recommended brake fluid to spe...

Page 44: ...re condition and tread depth Check air pressure Correct if necessary 6 17 6 19 Brake and shift pedals Make sure that operation is smooth Lubricate pedal pivoting points if necessary 6 28 Brake and clutch levers Make sure that operation is smooth Lubricate lever pivoting points if necessary 6 28 Sidestand Make sure that operation is smooth Lubricate pivot if necessary 6 29 Chassis fasteners Make su...

Page 45: ...OPERATION AND IMPORTANT RIDING POINTS 5 Starting and warming up a cold engine 5 1 Starting a warm engine 5 3 Shifting 5 3 Engine break in 5 5 Parking 5 6 ...

Page 46: ...round and distract the opera tor resulting in a possible loss of control EAU00376 CAUTION Make sure not to store personal items near the air cleaner in take otherwise air intake will be blocked and performance will suffer Make sure not to put anything near the battery and its termi nals otherwise electrical failure and acid corrosion may result EAU04219 Starting and warming up a cold engine In ord...

Page 47: ...ease the start switch wait a few seconds and then try again Each starting attempt should be as short as possible to pre serve the battery Do not crank the en gine more than 10 seconds on any one attempt _ ECA00101 CAUTION _ The engine trouble warning light should come on when the key is turned to ON and then go off after a few seconds If the engine trouble warning light comes on or flashes after s...

Page 48: ...nds with the starter choke turned on then about 2 5 min utes with the starter choke in the half way position _ EAU01258 Starting a warm engine Follow the same procedure as for start ing a cold engine with the exception that the starter choke is not required when the engine is warm EAU00423 Shifting Shifting gears lets you control the amount of engine power available for starting off accelerating c...

Page 49: ... To start out and accelerate 1 Pull the clutch lever to disengage the clutch 2 Shift the transmission into first gear The neutral indicator light should go out 3 Open the throttle gradually and at the same time release the clutch lever slowly 4 At the recommended shift points shown in the table on page 5 5 close the throttle and at the same time quickly pull the clutch lever in 5 Shift the transmi...

Page 50: ... acceleration and deceleration are shown in the table below CF 04E EAU01128 Engine break in There is never a more important period in the life of your engine than the period between 0 and 1 000 mi 1 600 km For this reason you should read the following material carefully Since the engine is brand new do not put an excessive load on it for the first 1 000 mi 1 600 km The various parts in the engine ...

Page 51: ...0 km and beyond The vehicle can now be operated normally EC000049 CAUTION If any engine trouble should occur during the engine break in period immediately have a Yamaha dealer check the vehicle EAU00457 Parking When parking stop the engine re move the key from the main switch and then turn the fuel cock lever to OFF EW000058 WARNING Since the engine and exhaust system can become very hot park in a...

Page 52: ...r free play 6 22 Adjusting the brake pedal position and free play 6 23 Adjusting the rear brake light switch 6 24 Checking the front brake pads and rear brake shoes 6 25 Checking the brake fluid level 6 26 Changing the brake fluid 6 27 Checking and lubricating the cables 6 27 Checking and lubricating the throttle grip and cable 6 27 Checking and lubricating the brake and shift pedals 6 28 Checking...

Page 53: ...NANCE SERVICES RELAT ED TO EMISSIONS CONTROL THESE CONTROLS NOT ONLY FUNCTION TO ENSURE CLEANER AIR BUT ARE ALSO VITAL TO PROPER ENGINE OPERATION AND MAXIMUM PERFORMANCE IN THE FOLLOWING PERIODIC MAINTE NANCE CHARTS THE SERVICES RELATED TO EMISSIONS CON TROL ARE GROUPED SEPARATE LY THESE SERVICES REQUIRE SPECIALIZED DATA KNOWLEDGE AND EQUIPMENT YAMAHA DEAL ERS ARE TRAINED AND EQUIPPED TO PERFORM T...

Page 54: ...ND MINOR REPAIR 6 2 6 EW000062 WARNING _ Modifications not approved by Yamaha may cause loss of perfor mance excessive emissions and render the vehicle unsafe for use Consult a Yamaha dealer before at tempting any changes _ ...

Page 55: ... adjust valve clearance when engine is cold 2 Spark plugs Check condition Adjust gap and clean Replace at 8 000 mi 13 000 km or 12 months Replace Replace 3 Crankcase ventilation system Check ventilation hose for cracks or damage Replace if necessary 4 Fuel line Check fuel hoses for cracks or damage Replace if necessary 5 Fuel filter Replace 6 Exhaust system Check for leakage Tighten if necessary R...

Page 56: ...00 mi 13 000 km or 12 months 3 Air filter element Clean or replace if necessary 4 Clutch Check operation Adjust or replace cable 5 Front brake Check operation fluid level and for fluid leakage See NOTE on page 6 6 Correct accordingly Replace brake pads if necessary 6 Rear brake Check operation Adjust cable and replace brake shoes if necessary 7 Final gear oil Check oil level and for oil leakage Re...

Page 57: ...ts and screws for tightness Tighten if necessary 14 Sidestand Check operation Lubricate pivot and contact surfaces with chain lube lightly 1 Repair if necessary 15 Sidestand switch Check operation Replace if necessary 16 Front fork Check operation and for oil leakage Repair if necessary 17 Rear shock absorber Check operation and for oil leakage Replace if necessary 18 Control and meter cable Apply...

Page 58: ... check and if necessary correct the brake fluid level Every two years replace the internal components of the brake master cylinder and caliper and change the brake fluid Replace the brake hoses every four years and if cracked or damaged Engine oil type Yamalube 4 20W 40 or engine oil SAE 20W 40 API SE for temperatures of 5 C 40 F or above Yamalube 4 10W 30 or engine oil SAE 10W 30 API SE for tempe...

Page 59: ...moving and installing panels The panels shown above need to be removed to perform some of the main tenance jobs described in this chapter Refer to this section each time a panel needs to be removed and installed 1 Panel A XVS650 1 Panel A XVS650A 1 Panel B ...

Page 60: ...he panel Remove the bolts and then take the panel off To install the panel Place the panel in the original position and then install the bolts EAU00491 Panel B To remove the panel Remove the bolt and then pull the pan el off as shown 1 Bolt 4 XVS650 1 Bolt 4 XVS650A 1 Bolt ...

Page 61: ... periodic mainte nance and lubrication chart In addition the condition of the spark plugs can re veal the condition of the engine To remove a spark plug 1 Remove the spark plug cap 2 Remove the spark plug as shown with the spark plug wrench includ ed in the owner s tool kit To check the spark plugs 1 Check that the porcelain insulator around the center electrode on each spark plug is a medium to l...

Page 62: ...p to specifica tion 2 Clean the surface of the spark plug gasket and its mating sur face and then wipe off any grime from the spark plug threads 3 Install the spark plug with the spark plug wrench and then tight en it to the specified torque NOTE If a torque wrench is not available when installing a spark plug a good estimate of the correct torque is 1 4 1 2 turn past finger tight However the spar...

Page 63: ... To check the engine oil level 1 Place the motorcycle on a level surface and hold it in an upright position NOTE _ Make sure that the motorcycle is posi tioned straight up when checking the oil level A slight tilt to the side can result in a false reading _ 2 Start the engine warm it up for several minutes and then turn it off 3 Wait a few minutes until the oil set tles and then check the oil leve...

Page 64: ...n under the engine to collect the used oil 3 Remove the engine oil filler cap and drain bolt to drain the oil from the crankcase NOTE _ Skip steps 4 7 if the oil filter element is not being replaced _ 4 Remove the outer and inner oil fil ter element covers by removing the bolts 1 Engine oil drain bolt 2 Oil pan 1 Oil filter element outer cover 2 Bolt 3 Right side 1 Oil filter element inner cover 2...

Page 65: ...r use oils of a CD grade or higher In addition do not use oils labeled ENERGY CONSERVING II or higher Make sure that no foreign mate rial enters the crankcase _ 10 Start the engine and then let it idle for several minutes while checking it for oil leakage If oil is leaking immediately turn the engine off and check for the cause 11 Turn the engine off and then check the oil level and correct it if ...

Page 66: ... be checked on a cold engine Make sure that the motorcycle is positioned straight up when checking the oil level A slight tilt to the side can result in a false read ing _ 2 Remove the oil filler bolt and then check the oil level in the final gear case NOTE _ The oil level should be at the brim of the filler hole _ 3 If the oil is below the brim of the fill er hole add sufficient oil of the rec om...

Page 67: ...fied in the periodic maintenance and lubrication chart Clean the air filter element more fre quently if you are riding in unusually wet or dusty areas 1 Remove the air filter case cover by removing the screws 2 Pull the air filter element out 3 Lightly tap the air filter element to remove most of the dust and dirt and then blow the remaining dirt out with compressed air as shown If the air filter ...

Page 68: ...the pistons and or cylinders may become excessively worn 5 Install the air filter case cover by aligning the match marks and in stalling the screws EAU00628 Adjusting the carburetors The carburetors are important parts of the engine and emission control sys tem which require very sophisticated adjustment Therefore all carburetor adjustments should be left to a Yamaha dealer who has the neces sary ...

Page 69: ...amaha dealer at the intervals specified in the periodic maintenance and lubrication chart EAU03360 Tires To maximize the performance durabil ity and safe operation of your motor cycle note the following points regarding the specified tires Tire air pressure The tire air pressure should be checked and if necessary adjusted before each ride EW000082 WARNING The tire air pressure must be checked and ...

Page 70: ...d cause tire damage an accident or even injury Tire inspection Always check the tires before operating the motorcycle If a tire tread shows crosswise lines minimum tread depth if the tire has a nail or glass fragments in it or if the sidewall is cracked con tact a Yamaha dealer immediately and have the tire replaced Tire air pressure measured on cold tires Load Front Rear Up to 90 kg 198 lb 200 kP...

Page 71: ...ooseness or dam age before each ride If any dam age is found have a Yamaha dealer replace the wheel Do not attempt even the smallest repair to the wheel A deformed or cracked wheel must be replaced The wheel should be balanced whenever either the tire or wheel has been changed or replaced An unbalanced wheel can result in poor performance adverse han dling characteristics and a short ened tire lif...

Page 72: ...he inherent stability of the orig inal design Genuine Yamaha Parts and Accessories are designed and tested to be compatible with your motorcycle Please consider Genu ine Yamaha Parts and Accessories before making a purchase Use of non Yamaha approved accessories or replacement parts may cause loss of handling stability and riding safety Since Yamaha cannot con trol the quality of accessories or pa...

Page 73: ...sting bolt in direction b 3 If the specified clutch lever free play could be obtained as de scribed above tighten the locknut and skip the rest of the procedure otherwise proceed as follows 4 Fully turn the adjusting bolt at the clutch lever in direction a to loos en the clutch cable 5 Loosen the locknut at the crank case 6 To increase the clutch lever free play turn the adjusting nut in di rectio...

Page 74: ...e play turn the adjusting bolt in direction b 3 Tighten the locknut EW000099 WARNING After adjusting the brake lever free play check the free play and make sure that the brake is working properly A soft or spongy feeling in the brake lever can indicate the presence of air in the hydraulic system If there is air in the hy draulic system have a Yamaha dealer bleed the system before operating the mot...

Page 75: ...op of the footrest as shown Periodi cally check the brake pedal position and if necessary adjust it as follows 1 Loosen the locknut at the brake pedal 2 To raise the brake pedal turn the adjusting bolt in direction a To lower the brake pedal turn the ad justing bolt in direction b 3 Tighten the locknut EWA00044 WARNING _ After adjusting the brake pedal posi tion the brake pedal free play must be a...

Page 76: ...direction b EAU00713 Adjusting the rear brake light switch The rear brake light switch which is ac tivated by the brake pedal is properly adjusted when the brake light comes on just before braking takes effect If necessary adjust the brake light switch as follows Turn the adjusting nut while holding the rear brake light switch in place To make the brake light come on earlier turn the adjusting nut...

Page 77: ...indicator grooves If a brake pad has worn to the point that the wear indicator grooves have almost disap peared have a Yamaha dealer replace the brake pads as a set EAU00727 Rear brake shoes The rear brake is provided with a wear indicator which allows you to check the brake shoe wear without having to dis assemble the brake To check the brake shoe wear check the position of the wear indicator whi...

Page 78: ...oir is level Use only the recommended quali ty brake fluid otherwise the rubber seals may deteriorate causing leakage and poor braking perfor mance Refill with the same type of brake fluid Mixing fluids may result in a harmful chemical reaction and lead to poor braking performance Be careful that water does not en ter the brake fluid reservoir when refilling Water will significantly lower the boil...

Page 79: ...the condition of the cables should be checked before each ride and the ca bles and cable ends should be lubricat ed if necessary If a cable is damaged or does not move smoothly have a Yamaha dealer check or replace it EW000111 WARNING Damage to the outer housing of ca bles may result in internal rusting and cause interference with cable movement Replace damaged ca bles as soon as possible to preve...

Page 80: ...and the pedal pivots should be lu bricated if necessary EAU03164 Checking and lubricating the brake and clutch levers The operation of the brake and clutch levers should be checked before each ride and the lever pivots should be lu bricated if necessary Recommended lubricant Lithium soap based grease all purpose grease Recommended lubricant Lithium soap based grease all purpose grease ...

Page 81: ...e up and down smoothly have a Yamaha dealer check or repair it EAU02939 Checking the front fork The condition and operation of the front fork must be checked as follows at the intervals specified in the periodic main tenance and lubrication chart To check the condition EW000115 WARNING Securely support the motorcycle so that there is no danger of it falling over Check the inner tubes for scratches...

Page 82: ...ealer check or re pair it EAU00794 Checking the steering Worn or loose steering bearings may cause danger Therefore the operation of the steering must be checked as fol lows at the intervals specified in the pe riodic maintenance and lubrication chart 1 Place a stand under the engine to raise the front wheel off the ground EW000115 WARNING Securely support the motorcycle so that there is no danger...

Page 83: ...101 CAUTION _ Never attempt to remove the battery cell seals as this would permanent ly damage the battery _ EW000116 WARNING _ Electrolyte is poisonous and dangerous since it contains sul furic acid which causes severe burns Avoid any contact with skin eyes or clothing and al ways shield your eyes when working near batteries In case of contact administer the fol lowing FIRST AID EXTERNAL Flush wi...

Page 84: ...2 If the battery will be stored for more than two months check it at least once a month and fully charge it if necessary 3 Fully charge the battery before in stallation 4 After installation make sure that the battery leads are properly con nected to the battery terminals EC000102 CAUTION _ Always keep the battery charged Storing a discharged battery can cause permanent battery damage To charge a s...

Page 85: ...ed amperage EC000103 CAUTION _ Do not use a fuse of a higher amper age rating than recommended to avoid causing extensive damage to the electrical system and possibly a fire _ 3 Turn the key to ON and turn on the electrical circuit in question to check if the device operates 4 If the fuse immediately blows again have a Yamaha dealer check the electrical system 1 Fuse box 2 Main fuse 3 Spare main f...

Page 86: ...nnect the headlight coupler and then remove the bulb cover 3 Unhook the headlight bulb holder and then remove the defective bulb EW000119 WARNING _ Headlight bulbs get very hot There fore keep flammable products away from a lit headlight bulb and do not touch the bulb until it has cooled down _ 4 Place a new headlight bulb into position and then secure it with the bulb holder 1 Screw 2 1 Headlight...

Page 87: ...cloth moistened with alcohol or thinner _ 5 Install the headlight bulb cover and then connect the coupler 6 Install the headlight unit by install ing the screws 7 Have a Yamaha dealer adjust the headlight beam if necessary EAU00855 Replacing a turn signal light bulb or the tail brake light bulb 1 Remove the lens by removing the screws 2 Remove the defective bulb by pushing it in and turning it cou...

Page 88: ...ion before starting any maintenance A strong wooden box can be placed un der the engine for added stability To service the front wheel 1 Stabilize the rear of the motorcycle by using a motorcycle stand or if an additional motorcycle stand is not available by placing a jack un der the frame in front of the rear wheel 2 Raise the front wheel off the ground by using a motorcycle stand To service the ...

Page 89: ... the wheel ECA00048 CAUTION _ Do not apply the brake after the wheel has been removed together with the brake disc otherwise the brake pads will be forced shut _ EAU03885 To install the front wheel 1 Install the speedometer gear unit into the wheel hub so that the pro jections mesh with the slots 2 Lift the wheel up between the fork legs NOTE _ Make sure that there is enough space between the brak...

Page 90: ...ycle so that there is no danger of it falling over 1 Loosen the axle nut 2 Disconnect the brake torque rod from the brake shoe plate by re moving the bolt 3 Loosen the brake torque rod bolt at the swingarm 4 Remove the brake pedal free play adjusting nut and then disconnect the brake rod from the brake cam shaft lever 5 Remove panel A See page 6 8 for panel removal and installation procedures Tigh...

Page 91: ...al joint 2 Install the final gear case bolts and then tighten them to the spec ified torque 3 Install the brake rod onto the brake camshaft lever and then install the brake pedal free play adjusting nut onto the brake rod 4 Install the brake torque rod bolt at the brake shoe plate and then tighten both bolts to the specified torque 5 Install the panel 6 Lower the rear wheel so that it is on the gr...

Page 92: ... systems for example can cause poor starting and loss of power The following troubleshooting chart represents a quick and easy procedure for checking these vital systems your self However should your motorcycle require any repair take it to a Yamaha dealer whose skilled technicians have the necessary tools experience and know how to service the motorcycle properly Use only genuine Yamaha replace m...

Page 93: ... compression Check the ignition Have a Yamaha dealer check the vehicle Remove the spark plugs and check the electrodes 3 Ignition Wipe off with a dry cloth and correct the spark plug gaps or replace the spark plugs Have a Yamaha dealer check the vehicle The engine does not start Have a Yamaha dealer check the vehicle The engine does not start Check the battery Operate the electric starter 4 Batter...

Page 94: ...MOTORCYCLE CARE AND STORAGE 7 Care 7 1 Storage 7 4 ...

Page 95: ... all caps and covers as well as all electrical couplers and connectors including the spark plug caps are tightly in stalled 3 Remove extremely stubborn dirt like oil burnt onto the crankcase with a degreasing agent and a brush but never apply such prod ucts onto seals gaskets and wheel axles Always rinse the dirt and degreaser off with water Cleaning ECA00010 CAUTION Avoid using strong acidic whee...

Page 96: ...eave any marks If the wind shield is scratched use a quali ty plastic polishing compound after washing After normal use Remove dirt with warm water a mild detergent and a soft clean sponge and then rinse thoroughly with clean water Use a toothbrush or bottlebrush for hard to reach areas Stubborn dirt and insects will come off more easily if the area is covered with a wet cloth for a few minutes be...

Page 97: ... by stones etc 6 Wax all painted surfaces 7 Let the motorcycle dry completely before storing or covering it EWA00031 WARNING Make sure that there is no oil or wax on the brakes or tires If necessary clean the brake discs and brake linings with a regular brake disc cleaner or ac etone and wash the tires with warm water and a mild deter gent Before riding at higher speeds test the motorcycle s braki...

Page 98: ...drain bolts this will prevent fuel deposits from building up Pour the drained fuel into the fuel tank 4 Fill up the fuel tank and add fuel stabilizer if available to prevent the fuel tank from rusting and the fuel from deteriorating 5 Perform the following steps to pro tect the cylinders piston rings etc from corrosion a Remove the spark plug caps and spark plugs b Pour a teaspoonful of engine oil...

Page 99: ...the wheels a little every month in order to prevent the tires from becoming degraded in one spot 8 Cover the muffler outlets with plas tic bags to prevent moisture from entering them 9 Remove the battery and fully charge it Store it in a cool dry place and charge it once a month Do not store the battery in an ex cessively cold or warm place less than 0 C 30 F or more than 30 C 90 F For more inform...

Page 100: ...SPECIFICATIONS 8 Specifications 8 1 ...

Page 101: ... height 710 mm 28 0 in Wheelbase 1 625 mm 64 0 in Ground clearance 145 mm 5 7 in Minimum turning radius 3 400 mm 133 9 in Basic weight with oil and full fuel tank XVS650 C 233 kg 514 lb XVS650A C 247 kg 545 lb Engine Engine type Air cooled 4 stroke SOHC Cylinder arrangement V type 2 cylinder Displacement 649 cm3 Bore stroke 81 63 mm 3 19 2 48 in Compression ratio 9 1 Starting system Electric start...

Page 102: ... Be sure to use motor oils that do not contain anti friction modifiers Passenger car motor oils often labeled ENERGY CONSERVING II contain anti friction additives which will cause clutch and or starter clutch slippage result ing in reduced component life and poor engine performance Spark plug Manufacturer model NGK DPR7EA 9 or DENSO X22EPR U9 Gap 0 8 0 9 mm 0 03 0 04 in Clutch type Wet multiple di...

Page 103: ...0 kPa 2 00 kgf cm2 29 psi Rear 250 kPa 2 50 kgf cm2 36 psi Total weight of rider passenger cargo and accessories XVS650A C Front Type Tube tire Size 130 90 16 M C 67S Manufacturer model Bridgestone G703 Dunlop D404F Rear Type Tube tire Size 170 80 15 M C 77S Manufacturer model Bridgestone G702 Dunlop D404G Maximum load 200 kg 441 lb Tire air pressure measured on cold tires Up to 90 kg 198 lb Front...

Page 104: ...Type Drum brake Operation Right foot Suspension Front Telescopic fork Rear Swingarm monocross Spring shock absorber Front Coil spring oil damper Rear Coil spring gas oil damper Wheel travel XVS650 C Front 140 mm 5 5 in Rear 86 mm 3 4 in XVS650A C Front 140 mm 5 5 in Rear 98 mm 3 9 in Electrical systems Ignition system T C I digital Charging system Type A C magneto Standard output 14 V 20 A 5 000 r...

Page 105: ... 27 8 W 2 Rear turn signal light 12 V 27 W 2 Meter lighting 12 V 1 7 W 1 Neutral indicator light 12 V 1 7 W 1 High beam indicator light 12 V 1 7 W 1 Turn signal indicator light 12 V 1 7 W 1 Engine trouble warning light 12 V 1 7 W 1 Fuses Main fuse 30 A Ignition fuse 10 A Signaling system fuse 10 A Headlight fuse 15 A Carburetor heater fuse 15 A ...

Page 106: ...1 Key identification number 9 1 Vehicle identification number 9 1 Model label 9 2 Reporting safety defects 9 3 Motorcycle noise regulation 9 4 Maintenance record 9 5 STREET AND ENDURO MOTORCYCLE LIMITED WARRANTY 9 7 YAMAHA EXTENDED SERVICE Y E S 9 9 ...

Page 107: ...EL LABEL INFORMATION CA 01E EAU01041 Key identification number The key identification number is stamped into the key tag Record this number in the space provided and use it for reference when ordering a new key EAU01043 Vehicle identification number The vehicle identification number is stamped into the steering head pipe Record this number in the space pro vided NOTE The vehicle identification num...

Page 108: ... to the frame under the rider seat See page 3 9 XVS650 or 3 11 XVS650A for rider seat removal and installation proce dures Record the information on this label in the space provided This infor mation will be needed when ordering spare parts from a Yamaha dealer 1 Model label ...

Page 109: ...aints it may open an investigation and if it finds that a safety defect exists in a group of vehicles it may order a recall and remedy campaign However NHTSA cannot become involved in individual problems between you your dealer or Yamaha Motor Corporation U S A To contact NHTSA you may either call the Auto Safety Hotline toll free at 1 800 424 9393 or 366 0123 in Washington D C area or write to NH...

Page 110: ...ted into any new ve hicle for the purpose of noise control prior to its sale or delivery to the ultimate purchaser or while it is in use or 2 the use of the vehicle after such device or element of design has been removed or rendered inoperative by any person AMONG THOSE ACTS PRESUMED TO CONSTITUTE TAMPERING ARE THE ACTS LISTED BELOW These acts include tampering with the following systems i e modif...

Page 111: ...rranty The chart below is printed only as a reminder that maintenance work is required It is not acceptable proof of maintenance work CL 04E Maintenance interval Date of service Mileage Servicing dealer name and address Remarks 600 mi 1 000 km or 1 month 4 000 mi 7 000 km or 6 months 8 000 mi 13 000 km or 12 months 12 000 mi 19 000 km or 18 months 16 000 mi 25 000 km or 24 months 20 000 mi 31 000 ...

Page 112: ... 6 9 28 000 mi 43 000 km or 42 months 32 000 mi 49 000 km or 48 months 36 000 mi 55 000 km or 54 months 40 000 mi 61 000 km or 60 months Maintenance interval Date of service Mileage Servicing dealer name and address Remarks ...

Page 113: ...CONSUMER INFORMATION 9 7 9 EAU02918 YAMAHA MOTOR CORPORATION U S A STREET AND ENDURO MOTORCYCLE LIMITED WARRANTY ...

Page 114: ...CONSUMER INFORMATION 9 8 9 ...

Page 115: ...CONSUMER INFORMATION 9 9 9 EAU01063 YAMAHA EXTENDED SERVICE Y E S ...

Page 116: ...CONSUMER INFORMATION 9 10 9 ...

Page 117: ...gear oil 6 14 Front fork checking 6 29 Fuel 3 7 Fuel cock 3 8 Fuel tank cap 3 6 Fuses replacing 6 33 H Handlebar switches 3 3 Headlight bulb replacing 6 34 Helmet holder 3 12 High beam indicator light 3 2 Horn switch 3 3 I Identification numbers 9 1 Ignition circuit cut off system 3 16 Indicator and warning lights 3 2 K Key identification number 9 1 L Labels location 1 7 Luggage strap holders 3 15...

Page 118: ...artment 3 13 Supporting the motorcycle 6 36 T Throttle cable free play adjusting 6 17 Throttle grip and cable checking and lubricating 6 27 Tires 6 17 Tool kit 6 1 Troubleshooting 6 40 Troubleshooting chart 6 41 Turn signal indicator light 3 2 Turn signal light or tail brake light bulb replacing 6 35 Turn signal switch 3 3 V Valve clearance adjusting 6 17 Vehicle identification number 9 1 W Warran...

Page 119: ...PRINTED ON RECYCLED PAPER YAMAHA MOTOR CO LTD PRINTED IN JAPAN 2001 5 3 0 1 CR E ...

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Yamaha XVS650, Owner'S Manual

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